Method of dyeing a textile product to achieve a desired appearance effect and textile product with appearance effect

ABSTRACT

A method of dyeing a textile product to achieve a desired appearance effect including the steps of applying an aqueous pretreatment composition of epoxy ammonium salt, caustic and wetting agent to a textile product in a selected manner to achieve a desired coverage of the pretreatment composition to the textile product, drying the textile product, dyeing the textile product to achieve an appearance effect corresponding to the selected manner of application of the pretreatment composition to the textile product. According to one preferred embodiment of the invention, the step of applying the pretreatment composition to the product is selected from the group of application methods which includes padding, spraying, brushing, dripping, writing and roller printing.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

[0001] This invention relates to a method of dyeing a textile product to achieve a desired appearance effect, and a related product produced by the method. In general, the process involves dyeing textile products after treating the textile product with an aqueous composition of an epoxy ammonium compound (referred to in this application as “PTC”), caustic and/or a wetting agent according to one of several disclosed methods. An example of the pretreatment solution is Amdye PTC which is commercially available from American Emulsions of Dalton, Ga. The components of the pretreatment solution are disclosed in U.S. Pat. Nos. 5,489,313 and 5,330,541. The present invention provides a process for dyeing fibers or fabrics without utilizing a salt as the dyebath exhausting agent. The invention is described in this application in relation to textile fabrics, which includes woven, knitted and non-woven products.

[0002] Known prior art processes using Amdye PTC pretreat the fabric by exhaustion or batching. In the present invention, pretreatment may be by any one of several application processes, including batching or continuous processing of the fabric while moving past an application station. By varying the manner in which the PTC is applied, numerous effects can be achieved when dyeing occurs, including fixed and random patterns and various combination shades, as described below. The invention is described principally with respect to use of reactive dyes, wherein effects which look like printing can be achieved using reactive dyes to dye materials which have been treated with PTC. A very soft “hand” is achieved in contrast to other processes, such as padding processes using pigment dyes. The process also permits virtually complete exhaustion of the dyestuff, thus eliminating discharge of dyestuff residue into wastewater systems.

SUMMARY OF THE INVENTION

[0003] Therefore, it is an object of the invention to provide a method of dyeing a textile product to achieve a desired appearance effect.

[0004] It is another object of the invention to provide a method of dyeing a textile product which utilizes an aqueous composition of an epoxy ammonium compound, caustic and/or a wetting agent according to one of several disclosed methods to achieve a desired appearance effect.

[0005] It is another object of the invention to provide a method of dyeing a textile product which can be carried out without salt and to dye exhaustion.

[0006] These and other objects of the present invention are achieved in the preferred embodiments disclosed below by providing a method of dyeing a textile product to achieve a desired appearance effect comprising the steps of applying an aqueous pretreatment composition of epoxy ammonium salt, caustic and wetting agent to a textile product in a selected manner to achieve a desired coverage of the pretreatment composition to the textile product, drying the textile product, dyeing the textile product to achieve an appearance effect corresponding to the selected manner of application of the pretreatment composition to the textile product.

[0007] According to one preferred embodiment of the invention, the step of applying the pretreatment composition to the textile product is selected from the group of application methods consisting of padding, spraying, brushing, dripping, writing and roller printing.

[0008] According to another preferred embodiment of the invention, the textile product is selected from the group consisting of woven fabric, nonwoven fabric and knitted fabric.

[0009] According to yet another preferred embodiment of the invention, the textile product is selected from the group consisting of woven or knitted garments, woven or knitted garment components, and knitted hosiery.

[0010] According to yet another preferred embodiment of the invention, the step of applying the pretreatment composition includes the step of moving the fabric past a stationary composition application station.

[0011] According to yet another preferred embodiment of the invention, the step of dyeing the fabric comprises the step of dyeing the fabric with a reactive dye.

[0012] According to yet another preferred embodiment of the invention, the step of applying the pretreatment composition comprises the step of differentially treating the fabric so that only some areas of the fabric receive the pretreatment composition.

[0013] According to yet another preferred embodiment of the invention, the step of applying the pretreatment composition comprises the step of differentially treating the fabric whereby some areas of the fabric receive a heavier application of pretreatment composition than other areas.

[0014] According to yet another preferred embodiment of the invention, the step of applying the pretreatment composition comprises pad batching the textile product, and further includes the steps of scouring and bleaching the pretreated textile product before drying.

[0015] According to yet another preferred embodiment of the invention, a method of dyeing a textile product to achieve a desired appearance effect is provided, and comprises the steps of applying an aqueous composition of caustic and wetting agent to a textile product, applying an aqueous composition of epoxy ammonium salt to the textile product treated in accordance with the caustic and wetting agent in a selected manner to achieve a desired coverage, drying the textile product, and dyeing the textile product to achieve an appearance effect corresponding to the selected manner of application of the pretreatment composition to the textile product.

[0016] According to yet another preferred embodiment of the invention, a dyed textile fabric is provided having a predetermined appearance effect resulting from being treated according to the method steps of applying an aqueous pretreatment composition of epoxy ammonium salt, caustic and wetting agent to the textile product in a selected manner to achieve a desired coverage of the pretreatment composition to the textile product, drying the textile product, and dyeing the textile product to achieve an appearance effect corresponding to the selected manner of application of the pretreatment composition to the textile product.

[0017] Preferably, the step of applying the pretreatment composition to the textile product is selected from the group of application methods consisting of padding, spraying, brushing, dripping, writing and roller printing.

[0018] According to yet another preferred embodiment of the invention, the textile product is selected from the group consisting of woven fabric, nonwoven fabric and knitted fabric.

[0019] According to yet another preferred embodiment of the invention, the textile product is selected from the group consisting of woven or knitted garments, woven or knitted garment components, and knitted hosiery.

[0020] According to yet another preferred embodiment of the invention, the step of applying the pretreatment composition includes the step of moving the fabric past a stationary composition application station.

[0021] According to yet another preferred embodiment of the invention, the step of dyeing the fabric comprises the step of dyeing the fabric with a reactive dye.

[0022] According to yet another preferred embodiment of the invention, the step of applying the pretreatment composition comprises the step of differentially treating the fabric so that only some areas of the fabric receive the pretreatment composition.

[0023] According to yet another preferred embodiment of the invention, the step of applying the pretreatment composition comprises the step of differentially treating the fabric whereby some areas of the fabric receive a heavier application of pretreatment composition than other areas.

[0024] According to yet another preferred embodiment of the invention, step of applying the pretreatment composition comprises pad batching the textile product, and further includes the steps of scouring and bleaching the pretreated textile product before drying.

[0025] According to one preferred embodiment of the invention, a dyed textile fabric is provided having a predetermined appearance effect resulting from being treated according to the method steps of applying an aqueous composition of caustic and wetting agent to a textile product, applying an aqueous composition of epoxy ammonium salt to the textile product treated with caustic and a wetting agent in a selected manner to achieve a desired coverage, drying the textile product, and dyeing the textile product to achieve an appearance effect corresponding to the selected manner of application of the pretreatment composition to the textile product.

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The file of this patent contains at least one drawing executed in color. Copies of this patent with color drawing(s) will be provided by the Patent and Trademark Office upon request and payment of the necessary fee.

[0027] Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the invention proceeds when taken in conjunction with the following drawings, in which:

[0028]FIGS. 1A, 1B and 1C are photographs of samples of a knitted interlock fabric processed in accordance with one process according to the invention;

[0029]FIG. 2 is a photograph of a sample of a double knit interlock fabric prepared with a drip PTC application process;

[0030]FIG. 3 is a photograph of a sample of a double knit rib shirt collar processed in accordance with one process according to the invention;

[0031]FIG. 4 is a photograph of a sample of a double knit interlock fabric processed with a double pad process according to the invention;

[0032]FIGS. 5A and 5B are photographs of a sample of a single knit jersey fabric processed with a ground dyeing and plastic sheet covering process according to the invention;

[0033]FIG. 6 is a photograph of a sample of a double knit interlock and rib shirt collar processed according to an embodiment of the invention;

[0034]FIG. 7 is a photograph of a sample of a double knit interlock fabric processed with two drip steps according to an embodiment of the invention;

[0035]FIG. 8 is a photograph of a sample of a “LaCoste” pattern knitted fabric processed with a padding step and a overfeeding wrinkle step according to an embodiment of the invention; and

[0036]FIG. 9 is a photograph of a sample of a double knit interlock knitted fabric processed with a batch step according to an embodiment of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE

[0037] Referring now specifically to the drawings, several examples of the method according to embodiments of the invention and products dyeing according to the process are shown and described. Each of the fabrics is cotton according to the described construction. However, any type of cellulosic fibers or silk can be processed as described in this application by adjusting the dye formulations.

[0038] The dyestuffs used are reactive dyes sold under the trademark “Splendid” by Man Fung International, Ltd, and are well known in the industry. Mc49 is a commonly used and readily available wetting agent. Direct dyes and acid dyes can also be used to achieve certain effects.

EXAMPLE 1

[0039] Material: Knitted Interlock Fabric Material: Knitted Interlock fabric 1) The fabric is first ground dyed in a pad batch step for 12 hours according to the following formula: a) Pad batch formula: PTC 30 g/l 50% NaOH 25 g/l Mc49 30 g/l b) The fabric is then scoured and bleached. c) The fabric is then dyed at 80° C. for 15 minutes with the dye formula: Splendid yellow CD-6G 1.09% Splendid yellow CD-3G 0.042% Soda Ash 2/gl d) The fabric is then rinsed and dried. The resulting solid shade dyed fabric is shown in FIG. 1A. Note the bright, clear and clean yellow color. 2) A special effect is achieved by: a) spraying one surface of fabric with: PTC 120 g/l 50% NaOH 80 g/l; b) drying the fabric at 270° F.; and c) dyeing the fabric at 80° C. for 15 minutes with: Splendid T. Blue BT 0.48%; and d) finishing and drying the fabric.

[0040] One face of the fabric is shown in FIG. 1B, and exhibits a solid dark green color. The reverse face is shown in FIG. 1C and exhibits a mottled light yellow-green color.

EXAMPLE 2

[0041] Material: Double knit interlock fabric 1) The fabric was pretreated by padding the fabric with: Wetter Mc-49 (wetting agent) 30 g/l 50% NaOH 80 g/l 2) Spots were applied to the fabric by dripping onto the fabric an aqueous solution of 120 g/l PTC 3) The fabric was then dried at 270° F. (130° C.) 4) The fabric was dyed at 80° C. for 15 minutes with the formula: Splendid Red CD-5B 0.02% Splendid B. Blue GD-GL .125%  0.2% Prefer Wet AFX (wetting agent)  0.7% Prefer Lev 400  0.5% 5) The fabric was then washed and dried.

[0042] The resulting fabric is shown in FIG. 2, and has a light blue ground with dark blue spots.

EXAMPLE 3

[0043] Material: Double knit Interlock and Rib Collars 1) The fabric was pretreated by padding with: 50% NaOH  75 g/l PTC 100 g/l 2) The fabric was then dried at 130° C. 3) The fabric was dyed at 80° C. for 15 minutes with the formula: Splendid Red CD-5B 0.28% Splendid Blue CD-GL  2.4% 4) The fabric was then washed and dried.

[0044] The resulting fabric is shown in FIG. 3, and has a blue overall shade with lighter colored areas giving the fabric an appearance which very closely resembles denim.

EXAMPLE 4

[0045] Material: Double knot interlock fabric 1) The fabric was padded in a first padding step with: 50% NaOH 75 g/l; 2) The fabric was then dried at 130° C.; 3) The fabric was padded in a second padding step with: PTC 100 g/l 4) The fabric was then dried at 130° C.; 5) The fabric was then dyed at 80° C. for 15 minutes with the formula: Splendid Red CD-5B 0.28% Splendid Blue CD-GL  2.4% 6) The fabric was then washed and dried.

[0046] The resulting fabric is shown in FIG. 4, and has a randomly distributed light and dark blue overall shade giving the fabric an appearance which very closely resembles stone-washed or faded denim.

EXAMPLE 5

[0047] Material: Single knit jersey fabric 1) The fabric was first ground dyed by a conventional dyeing method, and resin finished. See the solid yellow fabric shown in FIG. 5A. 2) The fabric was pretreated by spraying the fabric with: PTC 120 g/l 50% NaOH  80 g/l 3) The fabric was dried at 100° C.; 4) The fabric was then dyed at 80° C. for 15 minutes. The pattern was created by covering with plastic sheet during dyeing to cover a stripe while leaving an adjacent stripe exposed to full contact with the dyestuff. The dye formula was: Splendid Red CD-5B 1-2% Splendid Navy CD-FB 4.0% 5) The fabric was then washed and dried.

[0048] The resulting fabric is shown in FIG. 5B. Note the very dark green, almost black, stripe where the fabric was covered with plastic and the much lighter green stripe where the fabric was fully exposed to the dyestuff.

EXAMPLE 6

[0049] Material = Double knit interlock and Rib collar fabric 1) The fabric was pretreated by brushing the fabric and collars with random streaks and spots of the following composition: PTC 120 g/l 50% NaOH  80 g/l Wetter Mc-49 (wetting agent)  30 g/l 2) The fabric was batched for 12 hrs. 3) The fabric was scoured and bleached. 3) The fabric was dyed at 80° C. for 15 minutes with the formula: Splendid Red CD-5B 0.01% Splendid Blue CD-2L  0.1% Prefer Wet AFX  0.7% Prefer Lev 400  0.5% Soda Ash 2 g/l 4) The fabric was washed and dried.

[0050] The resulting fabric is shown in FIG. 6. The fabric has a white ground with medium purple streaks and spots. The colored areas penetrate completely into the depth of the fabric.

EXAMPLE 7

[0051] Material: Double knit interlock fabric 1) The fabric was pretreated in a first step by dripping onto the fabric an aqueous solution of: PTC 20 g/l 50% NaOH 20 g/l Wetter Mc-49 30 g/l; 2) The fabric was dried at 130° C.; 3) The fabric was pretreated in a second step by dripping onto the fabric an aqueous solution of: PTG 120 g/l 50% NaOH  80 g/l Wetter Mc-49  30 g/l 4) The fabric was dried at 130° C.; 5) The fabric was then dyed at 80° C. for 15 minutes according to the formula: Splendid Red CD-5B 0.02% Splendid Bill Blue CD-2L, 125%, 0.12% Prefer Wet AFX 0.7% Prefer Lev 400 0.5% 6) The fabric was washed and dried.

[0052] The resulting fabric is shown in FIG. 7. The fabric has a light purple ground with medium purple spots, dark purple spots and areas where light purple spots are surrounded by a “halo” of a darker purple.

EXAMPLE 8

[0053] Material: “LaCoste” pattern knitted fabric 1) The fabric was ground dyed optical white and resin finished. 2) The fabric was pretreated by padding with: PTC 120 g/l 50% NaOH  80 g/l 3) The fabric was dried at 130° C. while overfeeding to create a wrinkle effect. 4) The fabric was then dyed at 80° C. for 15 minutes with the formula: Splendid Red CD-5B 0.02% Splendid Brill Blue CD-2L 25%, 0.2% Prefer Wet AFX 0.7% Prefer Lev 400 0.5% Soda Ash 2 g/l 5) The fabric was then washed and dried.

[0054] The resulting fabric is shown in FIG. 8. The fabric a variety of random lines, stripes of varying shades resulting from the wrinkling of the fabric and the resulting differing concentration of PTC.

EXAMPLE 9

[0055] Material: Double knit interlock fabric 1) Pretreatment was accomplished with the following aqueous solution: PTC 100 g/l 50% NaOH  75 g/l Wetter MC-49  30 g/l 2) The fabric was covered with plastic to cover alternating stripes and batched for 12 hours with the uncovered stripes exposed to air. 3) The fabric was dyed at 80° C. for 15 minutes with the formula: Splendid Yellow CD-6G 2.0% Splendid Yellow CD-3G 1.5% 4) The fabric was then washed and dried.

[0056] As is illustrated by the above examples, the principal of the invention is utilizing the characteristics of PTC to alter the dye reaction characteristics of the fabric. This permits differential dyeing in ways not previously known in the art which result in fabrics which appear to be printed, but which have not been printed. Several process steps are saved, energy is saved and the resulting fabric has a soft, pliable hand which is quite desireable and a distinct contrast from the harsh, boardy feel of many printed fabrics. Crocking, shedding and other defects are reduced substantially if not eliminated altogether.

[0057] A method of dyeing a textile product to achieve a desired appearance effect, and a related product produced by the method is described above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the claims. 

I claim:
 1. A method of dyeing a textile product to achieve a desired appearance effect, and comprising the steps of: (a) applying an aqueous pretreatment composition of epoxy ammonium salt, caustic and wetting agent to a textile product in a selected manner to achieve a desired coverage of the pretreatment composition to the textile product; (b) drying the textile product; and (c) dyeing the textile product to achieve an appearance effect corresponding to the selected manner of application of the pretreatment composition to the textile product.
 2. A method of dyeing a textile product according to claim 1, wherein the step of applying the pretreatment composition to the textile product is selected from the group of application methods consisting of padding, spraying, brushing, dripping, writing and roller printing.
 3. A method of dyeing a textile product according to claim 2, wherein the textile product is selected from the group consisting of woven fabric, nonwoven fabric and knitted fabric.
 4. A method of dyeing a textile product according to claim 2, wherein the textile product is selected from the group consisting of woven or knitted garments, woven or knitted garment components, and knitted hosiery.
 5. A method of dyeing a textile product according to claim 2 or 3, wherein the step of applying the pretreatment composition includes the step of moving the fabric past a stationary composition application station.
 6. A method of dyeing a textile product according to claim 1, 2, 3, 4 or 5, wherein the step of dyeing the fabric comprises the step of dyeing the fabric with a reactive dye.
 7. A method of dyeing a textile product according to claim 1, wherein the step of applying the pretreatment composition comprises the step of differentially treating the fabric so that only some areas of the fabric receive the pretreatment composition.
 8. A method of dyeing a textile product according to claim 1, wherein the step of applying the pretreatment composition comprises the step of differentially treating the fabric whereby some areas of the fabric receive a heavier application of pretreatment composition than other areas.
 9. A method of dyeing a textile product according to claim 1, wherein the step of applying the pretreatment composition comprises pad batching the textile product, and further includes the steps of scouring and bleaching the pretreated textile product before drying.
 10. A method of dyeing a textile product to achieve a desired appearance effect, and comprising the steps of: (a) applying an aqueous composition of caustic and wetting agent to a textile product; (b) applying an aqueous composition of epoxy ammonium salt to the textile product treated in accordance with (a) in a selected manner to achieve a desired coverage; (c) drying the textile product; and (d) dyeing the textile product to achieve an appearance effect corresponding to the selected manner of application of the pretreatment composition to the textile product.
 11. A dyed textile fabric having a predetermined appearance effect resulting from being treated according to the method steps of: (a) applying an aqueous pretreatment composition of epoxy ammonium salt, caustic and wetting agent to the textile product in a selected manner to achieve a desired coverage of the pretreatment composition to the textile product; (b) drying the textile product; and (c) dyeing the textile product to achieve an appearance effect corresponding to the selected manner of application of the pretreatment composition to the textile product.
 12. A dyed textile product according to claim 11, wherein the step of applying the pretreatment composition to the textile product is selected from the group of application methods consisting of padding, spraying, brushing, dripping, writing and roller printing.
 13. A textile product according to claim 12, wherein the textile product is selected from the group consisting of woven fabric, nonwoven fabric and knitted fabric.
 14. A textile product according to claim 12, wherein the textile product is selected from the group consisting of woven or knitted garments, woven or knitted garment components, and knitted hosiery.
 15. A textile product according to claim 12 or 13, wherein the step of applying the pretreatment composition includes the step of moving the fabric past a stationary composition application station.
 16. A textile product according to claim 11, 12, 13, 14 or 15, wherein the step of dyeing the fabric comprises the step of dyeing the fabric with a reactive dye.
 17. A textile product according to claim 11, wherein the step of applying the pretreatment composition comprises the step of differentially treating the fabric so that only some areas of the fabric receive the pretreatment composition.
 18. A textile product according to claim 11, wherein the step of applying the pretreatment composition comprises the step of differentially treating the fabric whereby some areas of the fabric receive a heavier application of pretreatment composition than other areas.
 19. A textile product according to claim 11, wherein the step of applying the pretreatment composition comprises pad batching the textile product, and further includes the steps of scouring and bleaching the pretreated textile product before drying.
 20. A dyed textile fabric having a predetermined appearance effect resulting from being treated according to the method steps of: (a) applying an aqueous composition of caustic and wetting agent to a textile product; (b) applying an aqueous composition of epoxy ammonium salt to the textile product treated in accordance with (a) in a selected manner to achieve a desired coverage; (c) drying the textile product; and (d) dyeing the textile product to achieve an appearance effect corresponding to the selected manner of application of the pretreatment composition to the textile product. 